Nefas Silk Polytechnic College

Department of Electricity/Electronics

Mechatronics and Instrument Servicing Management

Level IV

Maintenance Management

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 1. Definition
• Maintenance operation management are the decisions and
actions regarding the control and upkeep of property and
equipment. These are inclusive, but not limited to, the following:
– actions focused on scheduling, procedures, and
work/systems control and optimization; and
– performance of routine, preventive, predictive, scheduled
and unscheduled actions aimed at preventing equipment
failure or decline with the goal of increasing efficiency,
reliability, and safety.

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 2. Why OM?
• Effective O&M (operations & maintenance)one of the most
cost-effective methods for ensuring reliability, safety, and
energy efficiency.
• Inadequate maintenance of energy-using systems is a major
cause of energy waste in industries.
• Energy losses from steam, water and air leaks, uninsulated
lines, maladjusted or inoperable controls, and other losses from
poor maintenance are often considerable.
• Good maintenance practices can generate substantial energy
savings and should be considered a resource. Moreover,
improvements to facility maintenance programs can often be
accomplished immediately and at a relatively low cost.

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 3. Planning MM
• A good way to start MM is by establishing a written
maintenance plan and obtaining upper management approval
as this gives same priority as other management actions.
• Approaching MM by equating it with increased productivity,
energy efficiency, safety, and customer satisfaction is one way
to gain management attention and support.
• When designing management reports, the critical metrics used
by each system should be compared with a base period. For
example, compare monthly energy use against the same month
for the prior year. If efficiency standards for a particular system
are available, compare your system’s performance against that
standard as well.

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 4. Metrics
• Metrics that can be used to evaluate maintenance program.
– Capacity factor – Relates actual plant or equipment operation to the
full-capacity operation of the plant or equipment.
– Work orders generated/closed out – Tracking of work orders
generated and completed over time allows the manager to better
understand workloads and better schedule staff.
– Backlog (accumulation) of corrective maintenance – An indicator of
workload issues and effectiveness of preventive/predictive maintenance
programs.
– Safety record – Commonly tracked either by number of loss-of-time
incidents or total number of reportable incidents. Useful in getting an
overall safety picture.
– Energy use – A key indicator of equipment performance, level of
efficiency achieved, and possible degradation.
– Inventory control – An accurate accounting of spare parts can be an
important element in controlling costs. A monthly reconciliation of
inventory “on the books” and “on the shelves” can provide a good
measure of your cost control practices. 5
 5. Types of maintenance programs
• Reactive Maintenance
– It is basically the “run it till it breaks” maintenance mode.
– No actions or efforts are taken to maintain the equipment as the
designer originally intended to ensure design life is reached.
– still the predominant mode of maintenance
– During the time we believe we are saving maintenance and capital
cost, we are really spending more dollars than we would have
under a different maintenance approach.
• While waiting for the equipment to break, we are shortening the
life of the equipment resulting in more frequent replacement.
• We may incur cost upon failure of the primary device associated
with its failure causing the failure of a secondary device.
• Our labor cost associated with repair will probably be higher
than normal because the failure will most likely require more
extensive repairs
• We will require a large material inventory of repair parts.

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 5. Types of maintenance programs
• Preventive Maintenance
– Actions performed on a time- or machine-run-based schedule that
detect, preclude, or mitigate degradation of a component or system
with the aim of sustaining or extending its useful life through
controlling degradation to an acceptable level.
– a means to increase the reliability of equipment
– By simply expending the necessary resources to conduct
maintenance activities intended by the equipment designer,
equipment life is extended and its reliability is increased.
– In addition to an increase in reliability, dollars are saved over that
of a program just using reactive maintenance.
– Studies indicate that this savings can amount to as much as 12% to
18% on the average.

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 5. Types of maintenance programs
• Predictive Maintenance
– Measurements that detect the onset of a degradation mechanism,
thereby allowing causal stressors to be eliminated or controlled
prior to any significant deterioration in the component physical
state. Results indicate current and future functional capability.
– Basically, predictive maintenance differs from preventive
maintenance by basing maintenance need on the actual condition
of the machine rather than on some preset schedule.
– Preventive maintenance is time-based such as changing lubricant
based on time, like calendar time or equipment run time. No
concern is given to the actual condition and performance capability
of the oil.
– If, on the other hand, the operator of the machine discounted the
machine run time and had the oil analyzed at some periodicity to
determine its actual condition and lubrication properties, he/she
may be able to extend or shorten the oil change time for good. This
is predictive maintenance.
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 5. Types of maintenance programs
• Predictive Maintenance
– Advantages
• Eliminate catastrophic equipment failures.
• Enable to schedule maintenance activities to minimize or delete
overtime cost.
• Minimize inventory and order parts
• Optimize the operation of the equipment, saving energy cost
and increasing plant reliability.
• Studies have estimated that a properly functioning predictive
maintenance program can provide a savings of 8% to 12% over
a program utilizing preventive maintenance alone.
– Disadvantages
• Predictive equipment requires cost in excess of $50,000
• Training of in-plant personnel to effectively utilize predictive
maintenance technologies will require considerable funding.

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 6. Reliability Centered Maintenance
• A process used to determine the maintenance requirements of
any physical asset in its operating context.
• It recognizes that all equipment in a facility is not of equal
importance and different equipment will have a higher probability
to undergo failures from different degradation mechanisms than
others.
• It also recognizing that a facility does not have unlimited
financial and personnel resources and that the use of both need
to be prioritized and optimized.
• The following maintenance program breakdowns of continually
top-performing facilities would echo the RCM approach to utilize
all available maintenance approaches with the predominant
methodology being predictive.
• <10% Reactive
• 25% to 35% Preventive
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• 45% to 55% Predictive
 7. Metering for Operations and Maintenance
• Metering for O&M and energy efficiency refers to the
measurement of quantities of energy delivered, for example,
kilowatt-hours of electricity, cubic feet of natural gas, pounds of
steam.
• Metering may also involve identifying times-of-use for the
various energy sources, the instantaneous demand for energy,
as well as identify energy use for a collection of buildings,
individual buildings, rooms, or specific equipment (e.g., a boiler,
chiller, or motor).
• The necessity to control costs, diagnose equipment
malfunction, allocate usage and set resource efficiency goals
are all increasingly important reasons for energy and water
metering.
• Metering provides the information that when analyzed allows
the building operations staff to make informed decisions on how
to best operate mechanical/electrical systems and equipment. 11
7. Metering for Operations and Maintenance (contd.)
• Reasons for metering vary by site; listed below are some
rational to consider for sub-metering at your site.
– Monitor existing utility usage
– Verify utility bills
– Identify the best utility rate plans
– Measure, verify, and optimize equipment performance
– Isolate energy use and costs
– Measure, not estimate, tenant energy use
– Diagnose equipment and systems operations
– Manage energy use.

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 8. O&M Ideas for Motor
• Motor systems consume about 70% of all the electric energy
used in the manufacturing sector.
• Thus efficiency improvement activities done on motors have
benefit.
• Motors can be purchased for varying application areas such as
for operating in a potentially gaseous or explosive area. When
purchasing a motor, be sure to check the classification of the
area, you may have a motor that does not meet the
classification it is presently in!
• Some general guidelines for efficient operations of electric
motors.
– Turn off unneeded motors
– Reduce motor system usage
– Sizing motors is important
– Replacement of motors versus rewinding 13
 8. O&M Ideas for Motor (contd.)
• Preventative and predictive maintenance programs for motors
are effective practices in manufacturing plants.
• These maintenance procedures involve a sequence of steps
plant personnel use to prolong motor life or foresee a motor
failure.
• The technicians use a series of diagnostics such as motor
temperature and motor vibration as key pieces of information in
learning about the motors.
• Common preventative tasks include routine lubrication, allowing
adequate ventilation, and ensuring the motor is not undergoing
any type of unbalanced voltage situation.

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Motor Maintenance Plan/Schedule (Example)
Description Comments Maintenance frequency
Dail Week Mont Annu
y ly hly ally
Motor Turn off/ sequence unnecessary motors X      
use/sequencing
Overall visual Complete overall visual inspection to be X      
inspection sure all equipment is operating and safety systems
are in place

Motor condition Check the condition of the motor through   X    

temperature or vibration analysis and compare to
baseline values

Check Assure that all bearings are lubricated per the     X  

lubrication manufacture’s recommendation

Check packing Check packing for wear and repack as necessary.     X  

Consider replacing packing with mechanical
seals.
Motor alignment Aligning the motor coupling allows for     X  
efficient torque transfer to the pump 15
 cont
Check mountings Check and secure all motor mountings     X  

Check terminal Tighten connection terminals as necessary     X  

tightness
Cleaning Remove dust and dirt from motor to     X  
facilitate cooling
Check bearings Inspect bearings and drive belts for wear.       X
Adjust, repair, or replace as necessary.
Motor condition Checking the condition of the motor       X
through temperature or vibration analysis
assures long life
Check for balanced Unbalanced power can shorten the motor       X
three-phase power life through excessive heat build up

Check for over- Over- or under-voltage situations can       X

voltage shorten the motor life through excessive
or under-voltage heat build up
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conditions